Paperboard pallet

ABSTRACT

A paperboard pallet is provided that includes first and second cardboard stringers positioned substantially parallel to each other. A space is formed between the first and second stringers. At least a first deck board is attached to and positioned substantially perpendicular to the first and second stringers. Both the first and second stringers include a notch on their top sides. Each notch on the top side of the first and second stringer is sized to receive the first deck board, and is located so a first side of the first deck board in each notch in the top side of the first and second stringers is located substantially flush with the first end of the first and second stringers.

RELATED APPLICATIONS

This application is a continuation-in-part application to U.S. patent application Ser. No. 14/203,042, filed Mar. 10, 2014, entitled “Paperboard Pallet” and claims the benefit of U.S. Provisional Application Ser. No. 61/897,987 filed Oct. 31, 2013, entitled “Paperboard Pallet—3” and claims the benefit of U.S. Provisional Application Ser. Nos. 61/776,553, filed Mar. 11, 2013, entitled “Paperboard Pallet” and U.S. Provisional Application Ser. No. 61/776,588, filed Mar. 11, 2013, entitled “Machine and Method for Making a Corrugated Paperboard Pallet” which are hereby incorporated by reference in their entirety.

TECHNICAL FIELD

The present disclosure relates to corrugated paper, cardboard, and/or fiber board pallets, as well as a method for making the same.

BACKGROUND AND SUMMARY

Conventional pallets are typically made of wood or plastic. Wood pallets consist of a plurality of spaced apart wood boards or stringers that are sandwiched between a plurality of spaced apart deck boards. These deck boards generally run parallel to each other and perpendicular to the stringers. When all the deck boards and stringers are nailed together, a secure platform is created that accommodates cargo, product, and other materials. In such wood pallet designs, spaces exist between the upper and lower deck boards that sandwich the stringers. These spaces are sized to accommodate forklift blades so that the products or materials setting on the pallet can all be lifted at one time when the forklift lifts the pallet.

The present disclosure is directed to a pallet made of cardboard or paperboard. Illustratively, the pallet may be made of corrugated cardboard. In one embodiment, a pallet may be made of cardboard stringers and deck boards. The stringers may be made of a composite of corrugated cardboard strips laminated together with glue to create a lightweight rigid structure. Similarly, the deck boards may be made from laminated strips of cardboard. The paperboard pallet provides a lightweight, high strength, solution for packing and/or warehousing product where a strong pallet is necessary but wood cannot be used because of issues such as insects in the pallet wood. For example, the food industry requires much of its packaged food product be stored and shipped on pallets, but insects in wood pallets pose a contamination risk. A paperboard pallet solution serves the pallet need, but does not have the issue with insects that a natural wood has.

Another illustrative embodiment of the present disclosure provides a paperboard pallet. The paperboard pallet comprises first and second stringers positioned substantially parallel to each other. Each of the first and second stringers is made of a plurality of bonded sheets of cardboard. A space is formed between the first and second stringers. Each of the first and second stringers has a top side, an underside, and a first end. The underside is located opposite the top side. At least a first deck board attached to the first and second stringers and positioned substantially perpendicular to the first and second stringers. Both the first and second stringers include a notch on their top sides. Each notch on the top side of the first and second stringer is sized to receive the first deck board. Each notch is also located so a first side of the first deck board in each notch in the top side of the first and second stringers is located substantially flush with the first end of the first and second stringers. Both the first and second stringers include a notch on their undersides. A second deck board is provided as well. Each notch on the underside of the first and second stringers is sized to receive the second deck board. These underside notches are also located so a first side of the second deck board is located substantially flush with the first end of the first and second stringers. A paper wrap is attached to the underside and sides of the first and second stringers, the second deck board, and spans the space formed between the first and second stringers.

In the above and additional embodiments, the paperboard pallet may further comprise: the cardboard is corrugated cardboard; a third stringer located in the space formed between the first and second stringers, which creates a second space in addition to the first space, wherein the space and the second space are each sized to receive a forklift fork; both of the first and second stringers have a second end located opposite the first end; a second deck board positioned substantially parallel to and spaced apart from the first deck board; a second notch on the top side of each of the first and second stringers, wherein each second notch on the top side of the first and second stringers is sized to receive the second deck board; the second deck board is fitted in the second notch on the top side of each of the first and second stringers, wherein the deck board is substantially flush with the topside of the first and second stringers; the paper wrap is selected from the group consisting of paper, kraft paper, and cardboard; the paper wrap includes first and second forklift openings that coincide with forklift openings in the first and second stringers.

Additional features and advantages of the paperboard pallet will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrated embodiment exemplifying the best mode of carrying out the paperboard pallet as presently perceived.

BRIEF DESCRIPTION OF DRAWINGS

The present disclosure will be described hereafter with reference to the attached drawings which are given as non-limiting examples only, in which:

FIG. 1 is a perspective view of an illustrative embodiment of a paperboard pallet;

FIG. 2 is a side view of the paperboard pallet of FIG. 1;

FIG. 3 is a side exploded view of the paperboard pallet of FIG. 1;

FIG. 4 is a perspective view of another illustrative embodiment of a paperboard pallet;

FIG. 5 is a side view of the paperboard pallet of FIG. 4;

FIG. 6 is a side exploded view of the paperboard pallet of FIG. 4;

FIG. 7 is a perspective view of another illustrative embodiment of a paperboard pallet;

FIG. 8 is a side view of the paperboard pallet of FIG. 7;

FIG. 9 is a side view of a stringer portion of the paperboard pallet of FIG. 7;

FIG. 10 is a front view of the paperboard pallet of FIG. 7;

FIG. 11 is a perspective view of another illustrative embodiment of a paperboard pallet;

FIG. 12 is a perspective view of another illustrative embodiment of a paperboard pallet;

FIG. 13 is a front partially disassembled view of the paperboard pallets of either FIG. 11 or 12;

FIG. 14 is a front view of the pallet of either FIG. 11 or 12;

FIG. 15 is an isolated view of a folded sheet that surrounds the paperboard pallet of either FIG. 11 or 12;

FIG. 16 is a top view of the paperboard sheet of FIG. 11 in an unfolded configuration;

FIG. 17 is a top view of the paperboard sheet of FIG. 12 in unfolded configuration;

FIG. 18 is a perspective view of another illustrative embodiment of a paperboard pallet;

FIG. 19 is an isolated front view of a folded sheet for use on the paperboard pallets of either FIG. 11, 12, or 18;

FIG. 20 is a top view of the paperboard pallet of FIG. 18;

FIG. 21 is a perspective view of an illustrative embodiment of an unassembled stringer composite;

FIG. 22 is a perspective view of another illustrative embodiment of a paperboard pallet;

FIG. 23 is a perspective view of a stringer used for the paperboard pallet in FIG. 22;

FIGS. 24A through C are perspective views of a deck board being wrapped;

FIG. 25 is a top view of a liner;

FIG. 26 is a side view of a flute that forms a deck board; and

FIG. 27 is a top view of a paperboard sheet in unfolded configuration.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates embodiments of the paperboard pallet and method of making, and such exemplification is not to be construed as limiting the scope of the paperboard pallet and method of making in any

DETAILED DESCRIPTION OF THE DRAWINGS

A perspective view of an illustrative embodiment of a paperboard pallet 2 is shown in FIG. 1. Pallet 2 includes parallel-spaced and spaced apart stringers 4, 6, and 8 sized as desired in relation to a desired pallet size. Attached transversely to the top surface of stringers 4, 6, and 8 are deck boards 10 and leading-edge deck boards 12 on the top side 14 of stringers 4, 6, and 8. It is appreciated in this embodiment that deck boards 10 and 12 are essentially flush with the top side 14 of stringers 4, 6, and 8. As shown in this view, the stringers 4, 6, and 8 may each include a plurality of forklift slots 16 and 18 which are illustratively in communication with spaces 20 and 22 also located adjacent stringers 4, 6, and 8, respectively. It is appreciated that forklift slots 16 and 18 are configured to receive the blades (not shown) of a standard forklift. On the underside of stringers 4, 6, and 8 are underside deck boards 24, 26, and 28. It is appreciated that end deck boards 24 and 28 form a leading edge on the underside of pallet 2 just as top deck boards 12 form leading edges on the top side of pallet 2. It is also appreciated from this view how the deck boards and stringers are spaced apart in similar fashion to a conventional pallet to provide an air of familiarity, yet are not made of solid wood boards.

A side view of pallet 2 is shown in FIG. 2. This view shows the shape of stringer 4 (like stringers 6 and 8) and how top deck boards 10 and 12, as well as underside deck boards 24, 26, and 28, have a top surface that is flush with top side 14 and bottom side 30 of stringer 4. Having deck boards in this configuration helps resist compression or crushing forces on the stringers when a load is applied to the deck boards. This view also includes stringer forklift cutouts 16 and 18. In an illustrative embodiment, the cutouts have a curved radius such as a 3 inch radius. This may help distribute the forces when a forklift blade lifts on the pallet, thereby moving the weaker point to a stronger part of the stringer. It is further appreciated that the laminations of corrugated cardboard may be 500# double wall corrugated board. In addition, the number of stringers on the top and the bottom may be more or less than what is shown herein, depending on the needs for the pallet.

A side exploded view of pallet 2 is shown in FIG. 3. This view demonstrates how notches 32 and 34 are cut into the top and bottom of the stringers, such as stringer 4 shown, so the deck boards maintain a flush appearance with the top side 14 and underside 30 of pallet 2. It is also appreciated that the dimensions of the stringers and deck boards may be varied, depending on the needed size of the pallet.

A perspective of another illustrative embodiment of a paperboard pallet 28 is shown in FIG. 4. It is appreciated that the use and configurations of the deck boards and stringers can be modified. Here, stringers 40, 42, and 44 include flush mounted deck boards 10 and 12 and include forklift slots 16 and 18 in communication with spaces 20 and 22. This embodiment also has a bottom sheet 46 that spans stringers 40, 42, and 44 on the underside of paperboard pallet 28. Bottom sheet 46 may help in resisting the bottom the stringers 40, 42, and 44, from separating during racking. Also, because as shown, bottom sheet 46 extends to the forklift holes 16 and 18, the sheet may also make these holes stronger. It is also appreciated that the forklift holes may be included on all sides of the pallet, including stringer 42. Spaces 20 and 22 may also have open ends so that a forklift may lift the pallet from any direction with respect to the pallet.

A side view of pallet 28 is shown in FIG. 5. This view shows how top deck boards 10 and 12 are substantially flush with the top surface of the stringers 40, 42, and 44. Also shown is corrugated bottom sheet 46 attached to the underside of stringers 40, 42, and 44. This view also shows forklift openings 16 and 18.

A side exploded view of pallet 28 is shown in FIG. 6. This view demonstrates the versatility in using deck boards and sheets. Similar to the prior embodiment, notches 48 may be cut into the stringer to create space for deck boards 10 and 12 to fit in the flush configuration. Bottom sheet 46 is attached to the underside of the stringers.

A perspective view of another illustrative embodiment of a paperboard pallet 50 is shown in FIG. 7. This embodiment includes top deck boards 10 and 12 sitting flush on stringers 52, 54, and 56 having similar spaces and openings like that previously discussed. This embodiment also has a bottom sheet 58 that spans the stringers 52, 54, and 56 to provide the bottom surface of pallet 50. In this embodiment, however, forklift holes 60 and 62 are disposed in stringers 52, 56, and 58, rather than being a cutout on the bottom of the stringers, as shown with the stringers in FIGS. 1 and 4.

A side view of pallet 50 is shown in FIG. 8. This view demonstrates how forklift holes 60 and 62, being disposed within stringer 52, are in contrast to the prior embodiments. Despite this change, pallet 50, and particularly stringer 52 (along with stringers 54 and 56) still accommodates deck boards 12 and 10 along with bottom sheet 58.

A side view of stringer 52 is shown in FIG. 9. This view demonstrates how the silhouette of stringer 52, as well as stringers 54 and 56, accommodates both notches 64, as well as forklift holes 60 and 62.

A front view of pallet 50 is shown in FIG. 10. This view helps demonstrate how stringers 52, 54, and 56 in combination with deck boards, such as deck boards 10 and 12 and bottom sheet 58, create a pallet that is familiar in its configuration, is lightweight, and durable while not being made of wood. This view also shows spaces 66 and 68 that accommodate forklift blades, as discussed in other embodiments such as spaces 20 and 22 of pallet 2. It is further appreciated that the deck boards may be made from a composite of many strips of corrugated cardboard laminated together with adhesives. Also illustratively, paper, such as craft paper, may be wrapped around the deck boards.

A perspective view of another illustrative embodiment of paperboard panel 70 is shown in FIG. 11. This embodiment includes stringers 72, 74, and 76 that are spaced apart from each other similar to prior embodiments, but are now wrapped in a folder-style corrugated sheet 78 that forms both the top deck and bottom of pallet 70.

A perspective view of another illustrative embodiment of a paperboard pallet 80 is shown in FIG. 12. Pallet 80 differs from pallet 70 in that the wrapped sheet 82 is used instead of wrapped sheet 78. As shown in this embodiment, wrapped sheet 82 is folded around stringers 84, 86, and 88 and does not include any openings on the top side surface. This provides a smooth continuous surface area for applications having such a need.

A front view of pallet 80 (like pallet 70) demonstrating how wrapped sheet 82 folds around stringers 84, 86, and 88, is shown in FIG. 13. In this embodiment, wrapped sheet 82 folds around to the underside of pallet 80 and includes end portions 90 and 92 which fold upward and adjacent one side of center stringer 86. In the embodiment shown, wrapped sheet 82 folds around the parallel spaced apart stringers 84, 86, and 88. Ends 90 and 92 fold up and are glued against side 94 of stringer 86, as also shown in the end view of FIG. 14. It is appreciated that in this configuration wrapped sheet 82 creates an offset positioning, as demonstrated by the front view of folded wrapped sheet 82 in FIG. 15.

Top views of cardboard sheets 78 and 82 in unfolded configurations are shown in FIGS. 16 and 17, respectively. As shown in FIG. 16, sheet 78 includes cut openings 122. Fold lines 124, 126, and 128 may be either scored or otherwise defined as the location where sheet 78 is folded to wrap around the stringers. Also, cut into sheet 78 are forklift openings 130. In the illustrative embodiment, underside openings 132 are cut in sheet 78 (and 82) to reduce material and gain access to the interior of the pallet. In similar fashion, sheet 82 includes score lines 124, 126, and 128 on each side, so sheet 82 may be wrapped around the stringers. In this embodiment, however, there are no cut openings like openings 122 in sheet 78. Instead, the top side of sheet 82 is a continuous surface. There are forklift openings 130 cut as shown, and end portions 90 and 92 are formed by score lines 128 also shown. It is appreciated that the cutouts may be useful even though they might reduce some strength. In certain instances, fire codes require holes in the pallets so water may filter through the pallets from top to bottom. In addition, the cutouts may reduce slippage on the surface. Alternatively, the deck surface may receive an anti-slick agent to reduce slippage. Further, the single sheet may be a 500# double-wall folded sheet of corrugated cardboard.

A perspective view of another illustrative embodiment of a paperboard pallet 100 is shown in FIG. 18. Paperboard pallet 100 is similar to pallet 80 from FIG. 12, but with the addition of deck boards 102 placed on the top. This embodiment includes stringers 84, 86, and 88, like the prior embodiment.

A front view of a partially folded wrapped sheet 82 (or wrapped sheet 78) is shown in FIG. 19. This view demonstrates how wrapped sheet 82 is folded to fit around the pallet forming an outer skin.

A top view of pallet 100 with deck boards 102 attached on top is shown in FIG. 18. It is appreciated that the horizontal corrugation provided by folded sheet 82, for example, may improve stringer strength. The stringers may also have improved strength by the addition of the corrugated deck boards 102 attached as shown. Such deck boards may also be attached to the underside (not shown) in similar configuration to that shown in FIG. 20.

A perspective view of an unassembled stringer 118 is shown in FIG. 20. In this illustrative embodiment, the aforementioned stringers are a composite of corrugated cardboard sheets, sandwiched together, and glued to form a high strength, low weight beam. Unassembled stringer 118 shows how in not all cases the sheets of cardboard need to be completely separate. In this case, score lines 120 may be made at regular intervals and the sheet cut into the desired stringer shape. In an accordion-like fashion, the cardboard may be folded into the stringer. The sheets are then glued together to form the final stringer board. Also shown are cutouts 122 that form the forklift holes in the stringers, as previously discussed in the prior embodiments.

Another illustrative embodiment of the present disclosure provides a paperboard pallet 200. Paperboard pallet 200 includes parallel-spaced apart stringers 204, 206, and 208. It is appreciated that they are sized as desired based on its use. Deck boards 210 extend transversely to the orientation of the stringers on the top and bottom surfaces. Leading edge deck boards 212 and 214 are similar construction to deck boards 210 except they are located on the top and bottom ends of paperboard pallet 200, respectively. Each deck board fits into a notch 215(see also FIG. 23) so that they become flush with the top surface 217 of each of the stringers 204, 206, and 208, providing a level top surface similar to that described in previous embodiments. Paperboard pallet 200 also includes forklift slots 216 and 218 formed in at least stringers 204 and 208. It is appreciated that stringer 206 may include forklift slots 216 and 218, as well to maintain modularity of assembling the pallet and/or because the forklift blades extend through the entire length of the pallet. It is appreciated that slots 216 and 218 are also formed in paperboard wrap 220 (see also FIG. 27). It is appreciated that bottom 222 of paperboard wrap 220 is attached hereto and sides 226 are attached to the sides of the stringers capturing the structures of the deck board. It is appreciated that an adhesive may be applied to stringers 204 and 208, as well as at the bottom and top deck boards to create a secure attachment between the pallet and paperboard sheet 220. This U-shape wrap on the pallet, as shown, may be used in an unsupported rack system in warehouses. The forces on the pallet may be better distributed throughout same by virtue of the U-shape wrap. Additionally, the U-shape wrap of sheet 220 may also prevent the stringers from collapsing or kicking out at the sides when substantial weight is applied.

A perspective view of an illustrative embodiment of stringers 204, 206 or 208 is shown in FIG. 23. This view shows the configuration of the stringer to accommodate the deck boards and forklift slots. As shown, deck boards are configured to fit into notches 215 on both tops of the stringer. In addition, lower notches 215 on the underside of the stringer may be employed to receive a deck board on the underside of the pallet. Employing underside deck boards increases the pallet's ability to withstand the rigors of moving on conveyors, as well as having added strength for racking. The dimensions of these stringers may be similar to those described for the previous embodiments and may include about 10 strips of corrugated board, or other paper glued together. The paper may also be scored in an accordion-like manner, as shown in FIG. 21. In an illustrative embodiment, the stringers may be about 47⅞ inches long by 5½ inches tall with a tolerance of about + or − 1/16 of an inch. Similar to prior embodiments, these stringers may be cut sheets of boards, such as corrugated or like board, laminated together using adhesive or other fastening material to provide a stringer with the appropriate strength and stiffness.

The several perspective views shown in FIGS. 24A through C include deck boards 210 or 212 wrapped with a craft-type paper wrapping 228. It is appreciated that deck board 210 and 212 may be formed by a plurality of paperboard, such as corrugated cardboard flutes 230 (see also FIG. 26) that are laminated together. In an illustrative embodiment, approximately 19-21 layers of these flutes 230 may be laminated together to form a deck board of desired width. In a further illustrative embodiment, the deck board may be 39¾ inches long by 5⅛ inches wide and about 1 inch tall. It is further appreciated that more flutes may be used depending on the desired use. It is also appreciated that in one embodiment the strips may be made by making multiple slices along the top surface of the sheet of corrugated cardboard which are then folded in an accordion-type manner (see FIG. 21 with respect to the stringer) to form the laminated deck board. As shown in FIGS. 24B and C, glue may be applied to a sheet of craft paper that can then wrap around at least three sides of the deck board. In another illustrative embodiment the wrap may wrap around all four sides of the deck board.

A top view of an unfolded liner 228 is shown in FIG. 25. This liner is configured to wrap around the deck board, as previously discussed. It is also appreciated that this size is configurable to match the size of the deck board.

A side view of an illustrative flute 230 is shown in FIG. 26. It is appreciated that the illustrative flute shape and size is illustrative and indicative of the final shape. It is appreciated, as discussed previously, that the flutes may be created in any variety of manners, including scoring cardboard and folding in an accordion-like fashion.

A top view of a paperboard shape wrap 220 is shown in FIG. 27. As discussed with respect to paperboard pallet 200 in FIG. 22, sheet 220 wraps around the bottom and side portions of pallet 220 in a U-shape configuration assisting in providing strength to the overall pallet. This embodiment, as shown in FIG. 27, includes mirror images of sheet 220 so that it may be folded over, thereby providing additional strength by doubling up on the sheet when forming into its U-shape configuration. Additionally, holes 234 may be formed in sheet 220 for use with a pallet jack.

Although the present disclosure has been described with reference to particular means, materials, and embodiments, from the foregoing description, one skilled in the art can easily ascertain the essential characteristics of the present disclosure and various changes and modifications may be made to adapt the various uses and characteristics without departing from the spirit and scope of the present invention as set forth in the following claims. 

What is claimed:
 1. A paperboard pallet comprising: first and second stringers positioned substantially parallel to each other; wherein each of the first and second stringers is made of a plurality of bonded sheets of cardboard; wherein a space is formed between the first and second stringers; wherein each of the first and second stringers has a top side, an underside, and a first end, wherein the underside is located opposite the top side; at least a first deck board attached to the first and second stringers and positioned substantially perpendicular to the first and second stringers; wherein both the first and second stringers include a notch on their top sides; wherein each notch on the top side of the first and second stringer is sized to receive the first deck board, and is located so a first side of the first deck board in each notch in the top side of the first and second stringers is located substantially flush with the first end of the first and second stringers; wherein both the first and second stringers include a notch on their undersides; a second deck board; wherein each notch on the underside of the first and second stringers is sized to receive the second deck board, and is located so a first side of the second deck board in each notch of the underside of the first and second stringers is located substantially flush with the first end of the first and second stringers; and a paper wrap is attached to the underside and sides of the first and second stringers and the second deck board, and spans the space formed between the first and second stringers.
 2. The paperboard pallet of claim 1, wherein the cardboard is corrugated cardboard.
 3. The paperboard pallet of claim 1, further comprising a third stringer located in the space formed between the first and second stringers, which creates a second space in addition to the first space, wherein the space and the second space are each sized to receive a forklift fork.
 4. The paperboard pallet of claim 1, wherein both the first and second stringers have a second end located opposite the first end.
 5. The paperboard pallet of claim 1, further comprising a second deck board, wherein the second deck board is positioned substantially parallel to and spaced apart from the first deck board.
 6. The paperboard pallet of claim 5, further comprising a second notch on the top side of each of the first and second stringers, wherein each second notch on the top side of the first and second stringers is sized to receive the second deck board.
 7. The paperboard pallet of claim 6, wherein the second deck board is fitted in the second notch on the top side of each of the first and second stringers, wherein the deck board is substantially flush with the topside of the first and second stringers.
 8. The paperboard pallet of claim 1, wherein the paper wrap is selected from the group consisting of paper, kraft paper, and cardboard.
 9. The paperboard pallet of claim 1, wherein the paper wrap includes first and second forklift openings that coincide with forklift openings in the first and second stringers. 